RU2694187C1 - Chocolate, chocolate products, a set for chocolate production and their production methods - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: invention relates to the food industry. Method of treating fermented or incubated cocoa beans or grit includes the steps of adding water to fermented or incubated cocoa beans or grit to produce a suspension, wet grinding of said suspension, thermal treatment of said suspension at temperature of 70 °C or lower. Suspension is separated into an aqueous phase (a heavy phase), a fat phase (light phase) and a solid phase. Said water phase contains cocoa aromatic substances and polyphenols. Said fat phase contains cocoa butter as main component and solid substances and/or water as secondary components. Said solid phase contains cocoa powder and water. Then, three phases are treated separately. Separate treatment of three phases includes neutralization of acetic acid formed during fermentation or formed or added before or during incubation of cocoa beans in an aqueous phase, and/or removal of acetic acid from the aqueous phase, separation of cocoa butter from the fat phase, separation of cocoa powder from the solid phase and separation of cocoa aroma substances and polyphenol powder from at least an aqueous phase. Also disclosed are a set for chocolate production, a method for production of chocolate or chocolate products and chocolate or chocolate product produced by this method.

EFFECT: invention allows to produce chocolate products with more pronounced cacao aroma.

15 cl, 4 dwg, 2 tbl

Description

TECHNICAL FIELD

[0001] The present invention relates to improved methods and / or technologies for making chocolate or chocolate products. In some embodiments, the present invention relates to methods for treating cocoa beans and making chocolate using fermented or incubated cocoa beans, which produce chocolate or chocolate products with improved flavor characteristics and / or higher levels of antioxidants and / or vitamins.

BACKGROUND

[0002] The types of methods and stages of processing cocoa beans into appropriate food products have a significant impact on the various qualities of the cocoa products obtained, such as taste, saturation or the content of antioxidants or vitamins, and even the product yield. For this reason, the method of processing cocoa beans into cocoa products (for example, food) can be crucial for commercial value, as well as the success or perception of such products (in the market or for use in other products).

[0003] A typical method of processing cocoa beans begins with the harvesting of beans, followed by fermentation and drying of cocoa beans. After collecting the cocoa fruit, you must carefully remove the beans from the fruit, while avoiding damage to the beans, as improper handling can damage the beans and lead to a decrease in the quality of the product during fermentation and roasting. Cocoa fermentation, like most organic materials, begins almost immediately when exposed to air. As a result of sedimentation of wild yeast spores on sugar-containing beans, sugar splitting into carbon dioxide, aromatics and alcohol begins, the alcohol is further converted into acetic acid due to the activity of bacteria. At the final stage of this process (hereinafter referred to as the “natural fermentation process”), the embryo inside the cocoa bean loses its ability to germinate due to the presence of alcohol, acetic acid and heat released due to the activity of microorganisms, resulting in the release of enzymes that reduce the tartness of the beans that is important for the development of chocolate flavor. As a rule, this natural cocoa fermentation process, spontaneously caused by the activity of microorganisms, takes about two or more days to suppress the activity of microorganisms due to an excess of acetic acid and / or heat released by the activity of microorganisms.

[0004] After preparation for further processing, fermented and dried cocoa beans are subjected to processes according to traditional or known methods, for example, described in patent publication PCT / JP2002 / 012064.

[0005] Since a significant portion of the acetic acid remains in the beans after the fermentation is completed, it must be removed from the beans to avoid the sour and bitter taste caused by the presence of acetic acid in the final cocoa product.

[0006] The above cocoa fermentation method (natural or spontaneous), caused by the spontaneous activity of microorganisms, is not the only way to prevent the sprouting of cocoa beans and, thus, to avoid the development of undesirable aromas as a result of the sprouting of cocoa beans. Germination of cocoa beans can be suppressed by using certain physical and / or chemical pretreatment of freshly harvested cocoa beans shortly after the beans have been extracted from the fruit. In particular, it is possible to suppress the germination of cocoa beans by incubating freshly harvested cocoa beans at an elevated temperature, for example, at a temperature of 25-70 ° C for less than two days. If this incubation is not carried out under sterile (aseptic) conditions, spontaneous activity of microorganisms may occur for at least a certain period of time after the extraction of cocoa beans from the fruit before the activity of the microorganisms ceases as a result of incubation. In the latter case, acetic acid is formed as a result of the activity of microorganisms (despite the fact that the amount of acetic acid produced when incubating a certain amount of cocoa beans is usually less than the amount of acetic acid that is formed during the natural fermentation of the same amount of cocoa beans).

Biehl, Ernst Brunner, Detlef Passern, Victor C. Quesnel и Daniel Adomako, опубликованной в Journal of the Science of Food and Agriculture (J. Sci. Food Agric.) 1985, 36, стр. 583-598. Соответственно, при инкубировании неферментированных какао-бобов в присутствии уксусной кислоты целесообразно контролировать значение рН какао-бобов, чтобы значение рН находилось в определенном диапазоне для получения какао-бобов, обеспечивающих интенсивный вкус шоколада. Кроме того, аромат подвергнутых инкубированию какао-бобов зависит от температуры какао-бобов во время инкубирования. Соответствующий способ обработки какао-бобов известен из патента США 8501256 В2, указанный способ включает такие стадии, как: i) физическая предварительная обработка какао-бобов и ii) по меньшей мере одна обработка водной кислотной средой предварительно обработанных какао-бобов до тех пор, когда рН указанных какао-бобов достигнет значения 3,6-5,5, причем бобы подвергают инкубированию на стадии ii) при температуре 25-70°С в течение менее 24 часов. Согласно документу США 8501256 В2 указанная водная кислая среда может содержать неорганические или органические кислоты с преобладанием амфифильных кислот, однако особенно положительные результаты достигнуты с применением уксусной кислоты, поскольку было показано, что при достаточной концентрации она эффективно проникает в какао-бобы и сквозь биологические мембраны.[0007] In general, it is considered that the presence of acids plays an important role in the development of cocoa bean flavor. For example, it has been shown that pretreatment of cocoa beans in the presence of acetic acid can have a beneficial effect on the development of chocolate flavor, even without natural fermentation. Article VC Quesnel (Materials of the 1957 Cocoa Conference (Proceedings of "1957 Cocoa Conference"), pp. 150-155) showed that unfermented cocoa beans, incubated in the presence of acetic acid, have a more pronounced flavor, than cocoa beans, incubated without acetic acid. However, incubating cocoa beans in the presence of acetic acid can lead to a decrease in the intensity of chocolate flavor, if the concentration of acetic acid is too high, as described in the article "Acidification, Proteolysis and Flavor Potential in Fermenting Cocoa Beans", the authors

Biehl, Ernst Brunner, Detlef Passern, Victor C. Quesnel and Daniel Adomako, published in the Journal of Food and Agriculture (J. Sci. Food Agric.) 1985, 36, pp. 583-598. Accordingly, when incubating unfermented cocoa beans in the presence of acetic acid, it is advisable to control the pH value of the cocoa beans so that the pH value is in a certain range to produce cocoa beans that provide an intense chocolate flavor. In addition, the flavor of incubated cocoa beans depends on the temperature of the cocoa beans during incubation. An appropriate method for treating cocoa beans is known from US Pat. No. 8,501,256 B2, the method includes the steps of: i) physical pretreatment of cocoa beans and ii) at least one treatment with an aqueous acidic medium of pre-treated cocoa beans until The pH of these cocoa beans will reach a value of 3.6-5.5, and the beans will be incubated in stage ii) at a temperature of 25-70 ° C for less than 24 hours. According to US 8,501,256 B2, this aqueous acidic medium may contain inorganic or organic acids with a predominance of amphiphilic acids, however, particularly positive results have been achieved with the use of acetic acid, since it has been shown that, with sufficient concentration, it effectively penetrates cocoa beans and through biological membranes.

[0008] Typically, the concentration of acetic acid decreases during the roasting stage, usually at a temperature of 70-180 ° C, and the handshake. However, with excessively high concentrations of acetic acid in fermented beans, a decrease in the indicated concentration during frying and conching is insufficient, as a result, chocolate products have a high content of acid and bitterness, or harsh conditions are required (high temperatures, prolonged thermal exposure (for example, excessive roasting and long conching time) and / or the use of alkalizing agents to neutralize acidic components), which contribute to The content of antioxidants, aromatics and vitamins, the formation of undesirable by-products (for example, acrylamides) and, accordingly, the deterioration of the quality of cocoa butter.

[0009] In addition, for the above reasons, in traditional methods of making high-quality chocolate or chocolate products, only cocoa beans can be used, which are at very specific fermentation stages and have a specific consistency, which is difficult to accomplish due to the different methods of collection and drying, and also fermentation conditions.

[0010] Conching is generally considered an important step in the process for developing flavor and reducing viscosity of a product. However, due to maintaining the product at an elevated temperature for a relatively long time, conching is energy intensive. A method and apparatus for making chocolate with a reduced conching time or without a conching stage is described in document WO 2004/000028, which discloses a device in which a pre-mixer conveys chocolate flakes to a gear pump. Document EP 2180793 proposes the implementation of several specific mixing and grinding operations in order to increase productivity and to match the duration of the conching process and the speed at which the mixture is to be conched.

[0011] Another problem in the traditional processing of cocoa beans is the destruction of the cell structure of raw cocoa materials due to high mechanical loads and shear stresses and / or high temperature, which is used to extract cocoa fats. US 2002/034579 A1 discloses a method in which unfermented beans are specially processed to destroy cellular and subcellular structures, and then subjected to oxidation treatment to produce cocoa with a low aromatic content.

[0012] In this regard, document WO 2010/073117 discloses a method for treating cocoa beans, including preparing a suspension containing cocoa beans or cocoa nibs and water, wet grinding the suspended beans or grains in several stages, heating the suspension and decanting the suspension separating said suspension into an aqueous phase, a fatty phase and a solid phase in order to avoid softening the cocoa fat and the formation of grated cocoa during mechanical processing.

[0013] However, the problem of providing high-quality chocolate products with both excellent texture and a non-sour and non-bitter taste, which requires a shorter duration of conching to make in order to increase the efficiency of the manufacturing process and further reduce the heat treatment of cocoa beans, is still due way not considered.

[0014] Thus, it is necessary to provide methods and products that eliminate the above disadvantages.

SUMMARY OF INVENTION

[0015] the Present invention solves the specified task in the scope of the claims set forth in the present description. The advantages of the present invention are described in more detail below, the additional advantages are obvious to those skilled in the art upon studying the description of the invention.

[0016] In general, in one aspect, the present invention provides a method for treating fermented or incubated cocoa beans or cocoa nibs, characterized by the steps of: adding water to said non-fermented cocoa beans to form a suspension; wet grinding the specified suspension; heat treating said suspension at a temperature of 70 ° C or lower; dividing the suspension into three phases, namely the aqueous phase (heavy phase), the fatty phase (light phase) and the solid phase, wherein said fatty phase contains cocoa butter as a main component and solids and / or water as minor components, and said the solid phase contains cocoa powder and water; as well as a separate processing phase of the three phases, which includes the neutralization and / or removal of acetic acid formed during fermentation or formed or added before or during the incubation of cocoa beans in the aqueous phase and, optionally, the separation of cocoa butter from the fat phase, the separation of cocoa powder from the solid phase and the separation of the aromatic substances of cocoa and polyphenolic powder at least from the aqueous phase.

[0017] Another aspect of the present invention is to provide a chocolate making kit containing polyphenolic powder, cocoa powder, cocoa butter, and cocoa flavor extracts obtained using the cocoa beans / grains processing methods described above.

[0018] In another aspect, the present invention provides a method for making chocolate or chocolate products, comprising the steps of: adding water to cocoa beans or grains, which are fermented or incubated, to form a slurry; wet grinding the specified suspension; heat treating said suspension at a temperature of 70 ° C or lower; dividing the suspension into three phases, namely the aqueous phase (heavy phase), the fatty phase (light phase) and the solid phase, said fat phase containing cocoa butter as a main component and solids and / or water as minor components, and said the solid phase contains cocoa powder and water; and separate processing of the three phases, which includes the neutralization and / or removal of acetic acid formed during fermentation or formed or added before or during the incubation of cocoa beans in the aqueous phase, separation of cocoa butter from the fatty phase, separation of cocoa powder from the solid phase , and separating cocoa flavors and polyphenolic concentrate at least from the aqueous phase; re-combining cocoa flavor extract with cocoa butter extract; mixing recoloured extracts with cocoa powder extract, polyphenolic powder extract and / or powdered milk; and the conching of the mixture.

[0019] Another aspect of the present invention is chocolate or chocolate products obtained using the above methods or the above set for making chocolate.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In Figure 1, a method for processing fermented cocoa beans is shown schematically, up to providing a chocolate making set, as well as a subsequent method for making chocolate in accordance with the present invention.

[0021] Figure 2 schematically shows an example of processing the aqueous phase after phase separation.

[0022] Figure 3A schematically shows an example of a method for making dark chocolate / milk chocolate using fractions obtained after separating and processing the fat, solid and aqueous phases.

[0023] Figure 3B is a schematic representation of an example of a method for making white chocolate using fractions obtained after separating and processing the fatty, solid, and aqueous phases.

DETAILED DESCRIPTION OF THE INVENTION

[0024] The following describes illustrative embodiments of the present invention for a more complete understanding of the present invention.

The method of processing fermented cocoa beans and / or grains

[0025] The method of processing fermented cocoa beans and grains according to the first embodiment of the present invention generally comprises the steps of: adding water to the fermented or incubated cocoa beans to form a suspension; wet grinding the specified suspension; heat treating said suspension at a temperature of 70 ° C or lower; dividing the suspension into three phases, namely the aqueous phase (heavy phase), the fatty phase (light phase) and the solid phase, wherein said fatty phase contains cocoa butter as a main component and solids and / or water as minor components, and said the solid phase contains cocoa powder and water; as well as a separate processing phase of the three phases, which includes neutralization and / or removal of acetic acid formed during fermentation or formed or added before or during the incubation of cocoa beans in the aqueous phase, separation of cocoa butter from the fatty phase, separation of cocoa powder from solid phase and separation of cocoa aromatics and polyphenolic concentrate at least from the aqueous phase.

[0026] The expressions "separating cocoa butter from the fat phase" and "separating cocoa powder from the solid phase" refers to operations by which respectively the concentration of the main components of cocoa butter (in the fat phase) or cocoa powder (in the solid phase) is provided . The expression "separating cocoa flavors and polyphenolic powder at least from the aqueous phase" refers to the operation by which cocoa flavors and polyphenolic powder are extracted from the corresponding phase in a concentrated form. These operations may include, but are not limited to, for example, filtration, drying (for example, evaporation of residual water, optionally under vacuum) and / or centrifugation.

[0027] The implementation of a cocoa processing process typically begins with the production of a suspension of fermented or incubated cocoa beans or cocoa nibs by adding water before or during grinding the cocoa beans / grains. As a raw material, whole fermented or incubated beans or fermented or incubated beans can be used, which then undergo a “crumbling” stage, during which the beans are crushed into smaller particles that are not whole beans (eg, grains).

[0028] To obtain a suspension of cocoa beans / grains add water.

[0029] Despite the absence of specific limitations, the mass ratio of water and cocoa beans / grains in the resulting suspension is preferably from 1: 1 to 6: 1, more preferably from 2: 1 to 4: 1, particularly preferably about 3: 1, what is expedient from the point of view of manufacturability at subsequent stages (for example, pumping, grinding and phase separation is easier).

[0030] If it is necessary to introduce additional flavoring additives, alternative aqueous liquids can also be used as a source of water, preferably one or more liquids selected from coffee, tea and liquids with a water content of 60 to 95 wt.%, For example, fruit juices, fruit juice concentrates or milk. In this case, it is preferable that the water content of the suspension obtained is in the ratios indicated above. Since the thermal load at the further stages of the process is relatively low, temperature-sensitive flavoring substances originating from these liquids are stored and can interact favorably with the primary and secondary flavors of cocoa beans.

[0031] To obtain coffee-flavored cocoa products, coffee beans (whole or crushed, unroasted or roasted) can be mixed with fermented cocoa beans / grains during suspension in water, provided that the cocoa beans / grains form the main part mixture of beans, so that the content of coffee beans does not interfere or does not have a negative impact on the stage of wet grinding and phase separation. Preferably the content of coffee beans is less than 20% of the mass. in the calculation of the mixture of beans, more preferably less than 10% of the mass.

[0032] Cocoa beans / grains are subjected to one or more wet grinding steps, resulting in particles of beans preferably 50 μm or less, more preferably 40 μm or less, more preferably 20 μm or less. As a result of reducing the particle size of the beans to the specified range, the surface area of the bean particles being exposed is significantly increased, which makes it possible to more effectively soak the bean particles (for example, with water, rather than with a chemical solvent) to improve extraction results (for example, greater extraction of fats or lipids, aromatic substances and / or polyphenols). The particle size of the beans can be reduced, for example, using disk mills (for example, mills with a perforated disk), colloid mills (for example, gear colloid mills) or mills with corundum millstones. Preferably, at least at one stage of grinding, the cocoa bean cells are subjected to maceration for better wetting of the cocoa bean material with a solvent (water) due to an increase in the accessible surface area of cocoa beans subjected to maceration. The methods and devices used for wet grinding are not specifically limited provided that there is no unwanted emulsification due to significant frictional heat release or significant mechanical forces. For example, when using several grinding stages, a coarse wet grinding stage (for example, optionally with additional water) can be carried out using a perforated disc mill, and the coarsely ground suspension can be pumped into a fine-tooth grinding colloid mill.

[0033] After the wet grinding stage, the suspension is subjected to heat treatment at a temperature not higher than about 70 ° C to reduce the total heat load and prevent emulsification. From the point of view of the preferred balance between the yield of cocoa butter and the preservation of the required flavoring substances, such as aromatics, antioxidants and / or vitamins, heating temperatures of 43-65 ° C are preferred. For softening cocoa butter and / or improving mechanical phase separation, the range of heating temperatures of 45-50 ° C is particularly preferred. Wet grinding suspension may be heated using a scraper or tubular heat exchanger, but is not limited to them.

[0034] Thereafter, the phases are separated to obtain three phases, i.e., an aqueous phase (heavy phase), a fatty phase (light phase) and a solid phase, wherein said fatty phase contains cocoa butter as the main component and solids and / or water as minor components, and the specified solid phase contains cocoa powder and water. In addition, the solid phase may contain up to 30% of the mass. residual cocoa butter, preferably less than 27% by weight, more preferably less than 20% by weight. based on dry weight in general. For the mechanical separation of particles, it is preferable to use devices that use centrifugal forces, such as decanters or nozzle separators. For example, a decantation of a suspension can be performed to separate crude, large or massive solids from liquids (liquids), and then smaller and / or thin solids can be further separated from liquids and / or oily products can be separated from non-oily products. .

[0035] To improve the separation of the aqueous phase (heavy phase), the fatty phase (light phase) and the solid phase, several stages of separation and re-combination of the phases can be used. For example, the fatty phase obtained at the initial stage of decanting can be further filtered or centrifuged to separate the remaining fine particles or water from the fatty phase, and the fine particles and water thus obtained can be re-combined with water and solid phases obtained at the initial stage. decanting or at a later stage of processing the specified phases. In addition, the aqueous phase can be subjected to further purification steps, for example, by filtration using vacuum filters to remove fine particles and reduce the turbidity of the liquid.

[0036] After separating the three phases (for example, the aqueous phase (heavy phase), the fatty phase (light phase) and the solid phase), the phases can be processed separately to separate the cocoa butter (from the fatty phase), cocoa powder (from the solid phase ), cocoa aromatics (at least from the aqueous phase, optionally also from the solid phase) and polyphenolic concentrate (from the aqueous phase), as shown in Figure 1.

[0037] As stated above, the fatty phase (light phase) can be filtered (for example, using a vibrating screen) and / or delivered to a three-phase separator (for example, a centrifuge) to remove fine particles (which can optionally be added to the solid phase to or during the drying / roasting step) and residual water (which may optionally be added to the aqueous phase before extracting the aromatics). Cocoa butter is obtained by filtration of the purified fat phase.

[0038] (Wet) solid phase obtained after separation into three phases, can be optionally processed using a roller crusher with heating to reduce the particle size and start pre-drying. In addition, sugar, sugar syrup and / or fruit juices may optionally be added to the separated cocoa solids before drying to develop flavor during the drying / roasting process.

[0039] The solid phase obtained after separation into three phases can be carefully dried and simultaneously roasted at a temperature of 55-100 ° C, from the point of view of reducing the heat load and maintaining healthy ingredients, preferably at a temperature of 55-70 ° C with a reduced pressure to preserve the flavoring substances obtained from roasting, and other aromatic compounds. If necessary, these flavors and other aromatic compounds can be added to cocoa butter or later during the processing of cocoa beans during the extraction of aromatic substances from the aqueous phase.

[0040] The drying / roasting method is not specifically limited, drying / roasting can be performed, for example, in a tumble dryer.

[0041] In a preferred embodiment, the drying / roasting step is carried out in a mixing device described in document EP 0711505 A1 for conching the chocolate mass. Said mixing device comprises a tubular body with a horizontal axis, the opposite ends of which are covered by end plates, a coaxial heating or cooling jacket through which, for example, diathermal oil or other fluid is directed to maintain the desired temperature of the inner wall of the body. The tubular body has an inlet and outlet for the solid phase. The outlet is communicated via a channel with a device for separating the aromatic phase from the dried product. The device further comprises a blade rotor to ensure rotation in the tubular body, the rotor blades are arranged in a spiral and directed to centrifuge the processed solid phase and simultaneously transport it to the outlet. The use of this mixing device allows you to continuously perform the stage of drying / roasting and separation of aromatic substances obtained as a result of roasting, and other aromatic compounds, and also significantly speeds up the processing of cocoa beans to cook cocoa powder (cocoa solids), which ensures the processing time less 20 minutes, usually less than 15 minutes.

[0042] In the cocoa bean / grain processing methods described above, the majority of the acetic acid formed during fermentation or formed or added before or during the incubation of the cocoa beans is in the aqueous phase and can thus be conveniently neutralized and / or removed by appropriate treatment of the aqueous phase after phase separation. For this reason, water-soluble acids can be added prior to phase separation in any required amount that is deemed appropriate from the point of view of adjusting the pH value and / or with the aim of improving flavor development in cocoa beans or grains, as adding does not necessarily lead to sour or bitter taste. in the final product.

[0043] The method for removing free acetic acid from the aqueous phase is not particularly limited, any suitable method known in the art can be used. For example, acetic acid can be removed from the aqueous phase by distillation (for example, extractive distillation or reactive distillation), extraction (for example, liquid-liquid extraction), processes using an emulsion liquid membrane, salting out, or a combination of these. Alternatively, acetic acid may remain in the aqueous phase if cocoa aromatics and polyphenolic powder are selectively extracted from it. As shown in Figure 2, the free acetic acid and, optionally, other water-soluble components can be removed from the aqueous phase before or during the dearomatization step and / or before or during the concentration step.

[0044] Neutralization and / or removal of free acetic acid from the aqueous phase has significant advantages over known methods, some of which will be discussed later.

[0045] Acetic acid is extracted from cocoa beans or grains from the aqueous phase prior to the drying / roasting of the solid phase. Therefore, the evaporation of acetic acid does not require long-term drying / roasting and significant heat treatment of fermented cocoa beans, resulting in a high content of aromatic substances, antioxidants, and vitamins. The duration of the conching process can also be significantly reduced.

[0046] In addition, the energy savings due to heating at lower temperatures, shorter drying / roasting and conching steps far outweigh the relatively high costs associated with using water and removing it, therefore the method according to the present invention also provides economic advantages compared with traditional methods of making cocoa products.

[0047] At the same time, unlike the traditional manufacture of cocoa products, cocoa beans with a relatively high content of acetic acid and / or various degrees of fermentation can be used to produce high-quality cocoa products, such as chocolate.

[0048] Another advantage of the present invention is that undesirable hydrophilic components (such as bitter and / or astringent properties of low molecular weight polyphenols (for example, catechins)) can also be removed from the aqueous phase.

[0049] In addition, it was found that the aqueous phase obtained in the decantation step also contains the desired aromatics that can be recovered from the first stage of concentration of the aqueous phase to produce aromatics. Also, the extraction of cocoa aromatics can be performed by countercurrent distillation (for the separation of aromatics and water).

[0050] In the optional second concentration phase, excess water can be evaporated to form a polyphenolic powder.

[0051] It is possible to remove unwanted water using evaporation methods, which result in the desired aromatic compounds suspended in water. In addition, it is possible to obtain concentrated polyphenols. In another embodiment, it is possible to increase the extraction of cocoa aromatics by countercurrent distillation (for example, to separate the aromatic components from water), which is preferably carried out at low pressure (less than 300 mbar) and at room temperature, to minimize thermal treatment.

[0052] As a rule, in the case of microorganism spoilage of materials extracted from cocoa (for example, cocoa butter, cocoa powder, cocoa aromatics and polyphenolic concentrate), this material can be deodorized using a vacuum deaerator. In addition, when contaminated with microorganisms, high pressure treatment is possible, for example, pascalization (it is expedient to preserve aromatics). However, in the event of both spoilage and microbial contamination, heat treatment and deodorization can be used. The method in accordance with the present invention allows fast processing of cocoa beans / grains, so that the growth of microorganisms is minimal.

[0053] Using the method (s) described herein, the cocoa beans can be efficiently processed to obtain the desired commercially significant yields of dried and extracted cocoa powder, cocoa butter with cocoa hydrophobic cocoa flavor, hydrophilic cocoa flavor and polyphenolic concentrates. In addition, some cocoa products obtained retain or contain the required levels of antioxidants and / or vitamins and / or contain more suitable (for example, less bitter) flavoring substances for which, in turn, no added sugar is required (or, at least , large amounts of sugar) when used in food products.

Chocolate Making Set

[0054] In the second embodiment of the invention, a chocolate making kit is proposed which contains a plurality of cocoa bean extraction products obtained in accordance with the steps of the method described above in the first embodiment of the invention. In other words, the kit for making chocolate in accordance with the present invention essentially contains polyphenolic powder, cocoa powder, cocoa butter and extracts of cocoa aromatics, obtained using the methods described above for processing cocoa beans / grains. Preferred embodiments of extracts (which can be arbitrarily combined) for use in a kit in accordance with the present invention are listed below.

[0055] In a preferred embodiment, the total concentration of 2-acetylpyrazine, methylpyrazine, tetramethylpyrazine, 2,3-dimethylpyrazine, 2,6-methylpyrazine, 2,5-dimethylpyrazine, trimethylpyrazine, ethylpyrazine, 2-ethyl-3-methylpyrazine, 2-ethyl -6-methylpyrazine, 2-ethyl-5-methylpyrazine, 2-ethyl-3,6-dimethylpyrazine, 2-ethyl-3,4-dimethylpyrazine, 2,3-diethyl-5-methylpyrazine, 2-isopropyl-3-methoxypyrazine , 2-isobutyl-3-methoxypyrazine, 2-ethyl-3,4-dimethylpyrazine, 1-methyl-1H-pyrrole, ethyl 2-methylbutanoate, 3-methylbutyl acetate, 2-heptanone, hexyl acetate, linalool, benzyl alcohol o alcohol, 2-phenylethanol, ethyl cinnamate, 2-phenethyl acetate, 2-phenyl-2-butenal, ethyl octanoate, 4-ethyl guaiacol, 4-vinyl guaiacol, vanillin, isobutanal, 2-methyl butanal, isovaleric aldehyde, acetoin, isophenyl, methylamine, 2-methylbutanal, isovaleric aldehyde, acetoin, acetone, 2-methylbutanal, 2-phenyl acetate acetylfuran, benzaldehyde, 5-methylfurfural, 2-furanmethanol, methional, phenylacetaldehyde and 4-methylphenol in cocoa butter is at least 5 mg / kg, more preferably at least 20 mg / kg, particularly preferably at least 40 mg / kg calculated on the total weight of cocoa butter. In another embodiment, the total concentration of acetic acid, propionic acid, isobutyric acid, 2-methylbutyric acid, 3-methylbutanoic acid and pentanoic acid in cocoa butter is preferably less than 15 mg / kg, more preferably less than 14 mg / kg, particularly preferably less than 13 mg / kg based on the total weight of cocoa butter.

[0056] In a preferred embodiment, the total concentration of 2-acetylpyrazine, methylpyrazine, tetramethylpyrazine, 2,3-dimethylpyrazine, 2,6-methylpyrazine, 2,5-dimethylpyrazine, trimethylpyrazine, ethylpyrazine, 2-ethyl-3-methylpyrazine, 2-ethyl -6-methylpyrazine, 2-ethyl-5-methylpyrazine, 2-ethyl-3,6-dimethylpyrazine, 2-ethyl-3,4-dimethylpyrazine, 2,3-diethyl-5-methylpyrazine, 2-isopropyl-3-methoxypyrazine , 2-isobutyl-3-methoxypyrazine, 2-ethyl-3,4-dimethylpyrazine, 1-methyl-1H-pyrrole, ethyl 2-methylbutanoate, 3-methylbutyl acetate, 2-heptanone, hexyl acetate, linalool, benzyl alcohol o alcohol, 2-phenylethanol, ethyl cinnamate, 2-phenethyl acetate, 2-phenyl-2-butenal, ethyl octanoate, 4-ethyl guaiacol, 4-vinyl guaiacol, vanillin, isobutanal, 2-methyl butanal, isovaleric aldehyde, acetoin, isophenyl, methylamine, 2-methylbutanal, isovaleric aldehyde, acetoin, acetone, 2-methylbutanal, 2-phenyl acetate acetylfuran, benzaldehyde, 5-methylfurfural, 2-furanmethanol, methional, phenylacetaldehyde and 4-methylphenol in cocoa powder is at least 8 mg / kg, more preferably at least 9 mg / kg, particularly preferably at least 10 mg / kg calculated on the total weight of cocoa powder. In another embodiment, the total concentration of acetic acid, propionic acid, isobutyric acid, 2-methylbutyric acid, 3-methylbutanoic acid and pentanoic acid in cocoa powder is preferably less than 60 mg / kg, more preferably less than 50 mg / kg, particularly preferably less 45 mg / kg based on the total weight of the cocoa powder.

[0057] In a preferred embodiment, the total concentration of 2-acetylpyrazine, methylpyrazine, tetramethylpyrazine, 2,3-dimethylpyrazine, 2,6-methylpyrazine, 2,5-dimethylpyrazine, trimethylpyrazine, ethylpyrazine, 2-ethyl-3-methylpyrazine, 2-ethyl -6-methylpyrazine, 2-ethyl-5-methylpyrazine, 2-ethyl-3,6-dimethylpyrazine, 2-ethyl-3,4-dimethylpyrazine, 2,3-diethyl-5-methylpyrazine, 2-isopropyl-3-methoxypyrazine , 2-isobutyl-3-methoxypyrazine, 2-ethyl-3,4-dimethylpyrazine, 1-methyl-1H-pyrrole, ethyl 2-methylbutanoate, 3-methylbutyl acetate, 2-heptanone, hexyl acetate, linalool, benzyl alcohol o alcohol, 2-phenylethanol, ethyl cinnamate, 2-phenethyl acetate, 2-phenyl-2-butenal, ethyl octanoate, 4-ethyl guaiacol, 4-vinyl guaiacol, vanillin, isobutanal, 2-methyl butanal, isovaleric aldehyde, acetoin, isophenyl, methylamine, 2-methylbutanal, isovaleric aldehyde, acetoin, acetone, 2-methylbutanal, 2-phenyl acetate acetylfuran, benzaldehyde, 5-methylfurfural, 2-furanmethanol, methional, phenylacetaldehyde and 4-methylphenol in the aromatic substance of cocoa is at least 800 mg / kg, more preferably at least 1 g / kg, particularly preferably at least 1.5 g / kg calculated on the total weight of the aromatic substance ka ao. In another embodiment, the total concentration of acetic acid, propionic acid, isobutyric acid, 2-methylbutyric acid, 3-methylbutanoic acid and pentanoic acid in the cocoa flavor is preferably less than 50 g / kg, more preferably less than 20 g / kg, particularly preferably less 5 g / kg based on total cocoa flavor.

[0058] In another preferred embodiment, the total concentration of 2-acetylpyrazine, methylpyrazine, tetramethylpyrazine, 2,3-dimethylpyrazine, 2,6-methylpyrazine, 2,5-dimethylpyrazine, trimethylpyrazine, ethylpyrazine, 2-ethyl-3-methylpyrazine, 2- ethyl-6-methylpyrazine, 2-ethyl-5-methylpyrazine, 2-ethyl-3,6-dimethylpyrazine, 2-ethyl-3,4-dimethylpyrazine, 2,3-diethyl-5-methylpyrazine, 2-isopropyl-3- methoxypyrazine, 2-isobutyl-3-methoxypyrazine, 2-ethyl-3,4-dimethylpyrazine, 1-methyl-1H-pyrrole, ethyl 2-methylbutanoate, 3-methylbutylacetate, 2-heptanone, hexyl acetate, linalool, ben yl alcohol, 2-phenylethanol, ethyl cinnamate, 2-fenetilatsetata, 2-phenyl-2-butene, etiloktanoata, 4-etilgvayakola, 4-vinilgvayakola, vanillin, isobutanal, 2-methylbutanal, isovaleraldehyde, acetoin, diacetyl, furfural, 2- acetylfuran, benzaldehyde, 5-methylfurfural, 2-furanmethanol, methional, phenylacetaldehyde and 4-methylphenol in the polyphenol powder is at least 1 mg / kg, more preferably at least 1.4 mg / kg, particularly preferably at least 1, 8 mg / kg based on the total weight of the polyphenolic powder. In another embodiment, the total concentration of acetic acid, propionic acid, isobutyric acid, 2-methylbutyric acid, 3-methylbutanoic acid and pentanoic acid in the polyphenolic powder is preferably less than 2 g / kg, more preferably less than 1 g / kg, particularly preferably less than 0 , 5 g / kg based on the total weight of cocoa powder.

[0059] The indicated total concentrations in each of the extracts can be determined by gas chromatography-mass spectrometry (GC-MS) methods known to those skilled in the art.

[0060] In another preferred embodiment, the total content of polyphenols in the cocoa powder is at least 20 mg ECE (equivalents of (-) - epicatechin) / g of defatted dry matter, more preferably at least 30 mg ECE / g of defatted dry matter, particularly preferably at least 40 mg ECE / g of dry fat. Preferably, the concentration of flavonoids in the cocoa powder is at least 10 mg ECE / g non-fat dry matter, more preferably at least 20 mg ECE / g non-fat dry substance, particularly preferably at least 30 mg ECE / g non-fat dry substance. In another preferred embodiment, the concentration of proanthocyanidin in the cocoa powder is at least 2 mg RCE (equivalents of procyanidin B2) / g of defatted dry matter, more preferably at least 3 mg REF / g of defatted dry matter, particularly preferably at least 4 mg PCE / g of dry fat.

[0061] In another preferred embodiment, the total polyphenol content of the polyphenol powder is at least 50 mg EEC / g of defatted dry matter, more preferably at least 60 mg ECE / g of defatted dry matter, particularly preferably at least 65 mg ECE / Mr. skim dry matter. Preferably, the concentration of flavonoids in the polyphenol powder is at least 20 mg ECE / g of dry fat, more preferably at least 30 mg ECE / g of dry fat, particularly preferably at least 35 mg ECE / g of dry fat. In another preferred embodiment, the concentration of proanthocyanidin in the polyphenol powder is at least 2 mg PCU / g of dry fat, more preferably at least 3 mg PCU / g of dry fat, particularly preferably at least 4 mg PCU / g of dry fat .

[0062] The total polyphenol content, as well as the concentration of flavonoids and proanthocyanidin, can be determined by conventional spectrophotometric methods known to those skilled in the art. For example, the total polyphenol content can be determined using Folin-Chokalteu reagent with (-) - epicatechin as a reference in accordance with the method described in Folin-Ciocalteu index, Off. J. Eur. Communities 1990, 41, 178-179 and Cooper et al., J. Agric. Food Chem 2008, 56, 260-265. The total content of flavonoids can be determined using a colorimetric analysis with a solution of aluminum chloride, for example, in accordance with Emelda et al. Int. J. ChemTech Res. 2014, 6 (4), 2363-2367, using (-) - epicatechin as a reference. For the spectrophotometric determination of the content of proanthocyanidin, the acid-butanol method (such as, for example, the Beit-Smith analysis or the Porter method) can be applied using the procyanidin B2 as a reference.

[0063] For an example illustrating the aromatic profile of the extracts, cocoa butter, cocoa powder, cocoa flavor and polyphenolic powder were prepared according to the exemplary scheme shown in Figure 1, from raw cocoa beans as raw materials that were roasted before obtain an aqueous suspension and without neutralization and / or removal of acetic acid from the aqueous phase.

[0064] The GC-MS method determined the number of different types of flavors in cocoa butter, cocoa powder and aqueous phase (and aromatic phase, respectively) obtained by the method in accordance with the present invention, as well as in commercially available cocoa powder and cocoa butter . In particular, the amount of fragrance with a raw / earthy smell was determined by the total concentration of 2-acetylpyrazine, methylpyrazine, tetramethylpyrazine, 2,3-dimethylpyrazine, 2,6-dimethylpyrazine, 2,5-dimethylpyrazine, trimethylpyrazine, ethyl pyrazine, 2-ethyl-3 -methylpyrazine, 2-ethyl-6-methylpyrazine, 2-ethyl-5-methylpyrazine, 2-ethyl-3,6-dimethylpyrazine, 2-ethyl-3,4-dimethylpyrazine, 2,3-diethyl-5-methylpyrazine, 2 -isopropyl-3-methoxypyrazine, 2-isobutyl-3-methoxypyrazine, 2-ethyl-3,4-dimethylpyrazine; fruit and flower flavors were quantitatively determined by the total concentration of 1-methyl-1H-pyrrole, ethyl-2-methylbutanoate, 3-methylbutylacetate, 2-heptanone, hexyl acetate, linalool, benzyl alcohol, 2-phenylethanol, ethyl cinnamate, 2-phenethyl acetate, 2 -phenyl-2-butenal and ethyl octanoate; spicy flavors were quantified by total concentrations of 4-ethyl guaiacol and 4-vinyl guaiacol; Malt / oil flavors were quantitated by total concentrations of vanillin, isobutanal, 2-methylbutanal, isovalerian aldehyde, acetoin, and diacetyl; baked / fried flavors were quantified by total concentrations of furfural, 2-acetylfuran, benzaldehyde, 5-methylfurfural, 2-furanmethanol, methional, phenylacetaldehyde, and 4-methylphenol; and pungent / acidic flavors were quantified by total concentrations of acetic acid, propionic acid, isobutyric acid, 2-methylbutyric acid, 3-methylbutanoic acid and pentanoic acid. The measurement results are presented in Table 1.

[0066] As shown in Table 1, the total content of flavors that are perceived as pleasant (for example, raw / earthy, fruity / floral, spicy and malted / fat / fried) is significantly higher in cocoa butter, obtained by the method in accordance with the present invention compared to commercially available cocoa butter. The same conclusions are made for cocoa powder, obtained by the method in accordance with the present invention, compared with the traditional method of cocoa powder. On the contrary, it has been shown that the concentration of acute / acidic flavoring agents in these extracts is significantly lower than in commercially available products, since a significant part of them remains in the aqueous phase. As a result of the removal and / or neutralization of acetic acid and other undesirable water-soluble components, it is easy to avoid unpleasant sour, bitter and / or tangy taste in the resulting products without degrading tastes that are perceived as pleasant.

[0067] For example, the content of polyphenols, flavonoids and proanthocyanidins in cocoa extracts and dark chocolate, obtained by the method shown in Figure 1, was also analyzed using Folin-Chokalteu reagent, analysis with aluminum chloride solution (in both cases using (-) - epicatechin as a reference) and the acid-butanol method (using procyanidin B2 as a reference). The results are shown in Table 2.

[0069] The methods of the present invention ensure that high extracts of polyphenols, flavonoids and / or proanthocyanidins present in cocoa beans are maintained in extracts, and as a result, in addition to a favorable aromatic profile, optimal amounts of healthy ingredients can be provided in the finished chocolate products.

[0070] Thus, a chocolate making kit in accordance with the present invention effectively provides raw materials for a wide range of high-quality chocolate products from which water-soluble unwanted hydrophilic components can be removed (such as providing low-molecular weight and / or astringent properties for low molecular weight polyphenols (for example, catechins)), while maintaining a high content of water-soluble aromatic components, polyphenolic components and vitamins present in both of beans / grits, and retain their high concentrations due to low heat treatment.

[0071] Thus, various choices of chocolate products can be obtained in which the typical characteristics, variety and variety of cocoa beans are perceived regardless of the specific degree of fermentation of the beans / grains used.

[0072] Examples of methods for making chocolate and chocolate products based on a set for making chocolate or extracts obtained by the method in accordance with the first embodiment, respectively, are given below.

Ways to make chocolate products

[0073] The cocoa bean extraction products, obtained in accordance with the steps of the method described in the first embodiment, can be used to prepare a wide range of chocolate products, as described later in the third embodiment.

[0074] Figure 3A shows an example of a method for preparing dark chocolate and milk chocolate, in which cocoa butter is first added to aromatic cocoa extracts obtained by dearomatising the aqueous phase, and / or optionally cocoa flavors obtained in the drying / roasting step (as shown in Figure 2). Before the conching stage, the dried and roasted hard cocoa powder is mixed with cocoa butter, to which aroma is added, and finely ground. If necessary, a polyphenol powder may be added to the mixture to provide a more intense taste and a higher content of antioxidants in the final product. Additionally, the taste can be changed or developed by adding one or more ingredients selected from sugars, sweeteners, cocoa pulp and / or fruit juices. To make milk chocolate, milk powder is additionally added, preferably before the mixing stage. Optionally, an emulsifier (eg, lecithin) may be added prior to conching to reduce viscosity, control sugar crystallization and chocolate flow, as well as homogeneous mixing of ingredients. In addition, additional ingredients and flavorings, such as, for example, vanilla, rum, and so on, can be added before or during the conching stage.

[0075] In the conching process, the substances that determine the taste are redistributed from the dry cocoa to the fatty phase, while the chocolate removes unwanted acetic, propionic and butyric acids, decreases moisture and softens the taste of the product. The temperature of conching is controlled and varies depending on different types of chocolate (from 49 ° C for milk chocolate to 82 ° C for dark chocolate). The duration of conching is somewhat dependent on temperature, but in traditional chocolate making processes, it is usually between 16 and 72 hours to ensure good results. In the method according to the present invention, the conching time is preferably less than 16 hours, more preferably less than 12 hours, typically 10 hours or less. Thus, there is no loss of the required taste characteristics, which is observed during prolonged conching.

[0076] Alternative chocolate products that can be made by the method of making chocolate in accordance with the present invention, as shown in Figure 3B, may be white chocolate, which is usually a mixture of cocoa butter, sugar, milk powder, emulsifier (for example , lecithin), as well as, optionally, vanilla to impart taste, depending on the manufacturer's recipes.

[0077] In traditional white chocolate manufacturing methods, deodorized cocoa butter is used. Cocoa butter is usually produced by methods involving treating grated cocoa with alkaline agents, resulting in a high content of bitter flavoring components in cocoa butter, which must be removed, which can be achieved by extraction with organic solvents or by injection of steam to obtain cocoa butter base with slight odor, without bitterness and tasteless for further preparation of white chocolate. However, it is known that as a result of these processes, a decrease in the content of vitamins and antioxidants in cocoa butter occurs.

[0078] It is preferable to obtain cocoa butter with fewer bitter flavoring additives, since it requires a slight processing of cocoa butter, if it is required at all, in order for the butter to be suitable for making white chocolate, which also preserves more of the required components, such as vitamins or antioxidants.

[0079] In addition, by re-combining cocoa butter with cocoa aromatics and / or roasted cocoa aromatics and / or polyphenol powder obtained by the method according to the first embodiment in accordance with the desired taste, white chocolate can be obtained that has a characteristic and tangible cocoa flavor.

[0080] Chocolate or chocolate products obtained by methods in accordance with the present invention can be given any suitable form, for example, packaged and sold as a block or bar, filled with filling and used as a glaze, used in other confectionery and bakery products (for example , as a glaze or cake filling, glaze or biscuit filling, glaze or filling of the cake layers or glaze for ice cream). In addition, the finished chocolate or chocolate products may optionally contain additional additives included before the final use of the product.

[0081] Many other characteristics, modifications and improvements are apparent to those skilled in the art from the above description of the invention.

Claims (38)

1. The method of processing fermented or incubated cocoa beans or grains, which includes stages: adding water to fermented or incubated cocoa beans or grains to form a suspension; wet grinding the specified suspension; heat treating said suspension at a temperature of 70 ° C or lower; separating the suspension into the aqueous phase (heavy phase), the fatty phase (light phase) and the solid phase, wherein said aqueous phase contains cocoa aromatics and polyphenols, said fatty phase contains cocoa butter as a main component and solids and / or water as minor components, and this solid phase contains cocoa powder and water; and separate processing of the three phases, which includes: neutralizing the acetic acid formed during fermentation or formed or added before or during the incubation of cocoa beans in the aqueous phase, and / or the removal of acetic acid from the aqueous phase, and separation of cocoa butter from the fat phase separation of cocoa powder from the solid phase and separating cocoa flavors and polyphenolic powder at least from the aqueous phase. 2. The method according to p. 1, characterized in that the acetic acid is removed from the aqueous phase by distillation, extraction, processes using an emulsion liquid membrane, salting out, or a combination thereof. 3. The method according to p. 1 or 2, characterized in that the aqueous phase is subjected to one or more stages of concentration to obtain these extracts of aromatic substances of cocoa and polyphenolic powder. 4. The method according to p. 3, characterized in that the acetic acid is removed from the aqueous phase before or during the stage (stages) concentration. 5. The method according to any of the preceding paragraphs, characterized in that the aromatic substances of cocoa and polyphenolic powder are extracted from the aqueous phase and the solid phase. 6. The method according to any one of the preceding claims, further comprising the step of drying the solid phase in a dryer after separation into three phases to obtain aromatic compounds and cocoa solids. 7. The method according to p. 6, characterized in that the dryer is a drum dryer. 8. The method according to p. 6, characterized in that the dryer is a mixing device comprising a tubular body having an inlet and outlet for the solid phase, the axis of which is horizontal and closed at opposite ends with end plates; a coaxial heating or cooling jacket and a blade rotor rotatably in a tubular body, the blades of which are arranged in a spiral and directed to centrifuge the processed solid phase and simultaneously transport it to the outlet, the outlet opening is connected through a channel with a device for separating the aromatic phase from the dried product for continuous drying of cocoa solids and separation of aromatics. 9. The method according to any one of the preceding claims, characterized in that the cocoa processing steps are carried out without the use of non-aqueous solvents. 10. The method according to any of the preceding paragraphs, characterized in that each of these stages of processing cocoa is carried out at temperatures not higher than 70 ° C. 11. Set for making chocolate, containing cocoa butter, cocoa powder, polyphenolic powder and extracts of cocoa aromatics, obtained by the method according to claim 1. 12. The method of producing chocolate or chocolate products, which includes stages: adding water to fermented or incubated cocoa beans or grains to form a suspension; wet grinding the specified suspension; heat treating said suspension at a temperature of 70 ° C or lower; dividing the suspension into three phases, i.e. the aqueous phase (heavy phase), the fatty phase (light phase) and the solid phase, said aqueous phase containing cocoa flavors and polyphenols, said fatty phase containing cocoa butter as a main component and solids and / or water as minor components, and the specified solid phase contains cocoa powder and water; and separate processing of the three phases, which includes: neutralization of acetic acid formed during fermentation or formed or added before or during incubation of cocoa beans in the aqueous phase, and / or removal of the specified acetic acid from the aqueous phase, separation of cocoa butter from the fat phase separation of cocoa powder from the solid phase and separating cocoa flavors and polyphenolic powder at least from the aqueous phase; re-combining cocoa flavor extract with cocoa butter extract; mixing recoloured extracts with said cocoa powder extract, said polyphenol powder extract and / or powdered milk; conching of the mixture and molding the conched mixture. 13. The method according to p. 10, characterized in that the re-combined extracts are mixed with at least the specified extract of cocoa powder and the specified extract of polyphenolic powder. 14. The method according to p. 12 or 13, characterized in that the re-combined extracts are further mixed with sugar, sweetener or cocoa pulp. 15. Chocolate or chocolate product obtained by the method according to any one of paragraphs. 12-14.

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